Enquiry No.

:
Due Date :
Bharat Heavy Electricals Limited Supplier's Ref.:
Date :

Part A (Techno-Commercial Bid) Section 3

Specification cum Compliance Certificate for AUTOMATIC LONGITUDINAL SEAM WELDING SPM
Scope: Design, Manufacturing, Supply, Erection & Commissioning of AUTOMATIC LONGITUDINAL SEAM WELDING SPM
complying with the following specification
S No. Description - BHEL's Requirement Specified Offered Deviations Remarks
1.0 PURPOSE & WORK PIECE MATERIAL
1.1 Purpose: Automatic Longitudinal Welding Full Welding
Aluminium
Alloy(Tensile strength
1.2 Work Piece Material: 2
35kgf/mm ) & mild
steel
2.0 SPECIFICATION
MACHINE CONFIGURATION:Automatic Longitudinal MIG
Welding Machine with Power Source 500 Amps @60% duty
cycle, Feed Unit, Mig Torch Assembly, Seam Tracking System,
2.1 Vendor to confirm
Motorized Side Beam Carriage Unit for Torch Manipulation,
Fixture for Job holding & resting, for Welding Aluminium Bus
Duct of size mention under clause 2.2.
Power Source:-Synergic Pulse MIG or Double Pulse MIG type Vendor to confirm and
from reputed manufacturer capable of giving Radiographic give details with
2.1.1
Quality welding in aluminium Alloy e.g. Lincoln Electric, OTC manufactures name &
Daihen. model
Vendor to confirm and
give details with
2.1.2 Wire Feed Unit -Suitable For above
manufactures name &
model
Vendor to confirm and
give details with
2.1.3 Torch Manipulation Unit
manufactures name &
model
Motorised Side Beam Carriage of stroke length approx. 2500 Vendor to confirm and
mm with Controlled speed through Variable frequency drive. give details with
2.1.4
This Unit should house entire Torch Manipulation Unit, Wire manufactures name &
Feeder Unit, Wire Spool Unit etc. model
Vendor to confirm and
give details with
2.1.5 Torch Weaving Unit
manufactures name &
model
2.1.6 Controlling Speed (Suitable for required welding) Vendor to specify
2.1.7 Welding Speed (Suitable for required welding) Vendor to specify
Job Holding Fixture:-It shall be such that the position of the
joints is maintained as per requirment of welding system
2.1.8 Vendor to confirm
supplied. The welded joint shall be NDT (X Ray, DP Test)
quality
Option to weld Discontinuous welding at gap 400-500mm with
2.1.9 Vendor to confirm
welding lenth 100mm-200mm
ESSENTIAL:-(a)Torch Weaving Unit for giving wider welding
2.1.10 Vendor to confirm
bead in a single pass having the following controls.

2.1.10.1 Weaving speed 150-1500 mm/min Vendor to confirm

2.1.10.2 Width Control Vendor to specify

2.1.10.3 Left/Right Dwell Control Vendor to specify

2.1.10.4 Centre shift control within the stroke length of the weaver Vendor to specify

2.1.10.5 Stroke length of the torch weaving unit 75 mm approx. Vendor to specify
ESSENTIAL: Video Monitoring System to capture the position in
two views while welding through Monitor, so that the operator
2.1.11 monitors the same in one place and adjusts the torch using Vendor to confirm
joystick for fine tuning while welding. This unit shall comprise
of :
2.1.11.1 CCTV Camera with accessories Vendor to confirm

2.1.11.2 Monitor Vendor to confirm

2.1.11.3 Interconnecting cable accessories Vendor to confirm

2.2 CAPACITY & SIZE
2.2.1 Drum Dia of Aluminium alloy At Following thickness
a At tk 8 / 9 mm Ø1000 - Ø1800
b At tk 15 / 16 mm Ø450 - Ø1030
c At tk 6.35 mm Ø780 - Ø1000
d At tk 4.78mm Ø680 - Ø780
2.2.2 Continuous Welding Length 2000 mm

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S No. Description - BHEL's Requirement Specified Offered Deviations Remarks
2.2.3 Motor Power Vendor to specify
2.2.4 Working Height from floor level Vendor to furnish
2.3 CONSTRUCTION:
Vendor to furnish details of material, hardness & constructional
details, including explanatory drawings, of various components like
2.3.1 Vendor to furnish
Torch, frame, clamping & adjusting system, Lubrication system, etc
.of the machine.
Video images on CD including hard copy explaining the technical
2.3.2 features / Literature with photographs, drawings explaining the Vendor to furnish
technical features should be enclosed with the offer.
The working principle of the above mechanism shall be explained
2.3.3 Vendor to Confirm
clearly.
Digital display of major weld parameters like current, voltage, wire,
2.3.4 Vendor to Confirm
speed, programme w.r.t. material / thickness etc
2.3.5 Any other feature if required Vendor to Confirm
3.0 OPERATION AND CONTROL SYSTEM:
3.1 CONTROL PANEL:
Control Panel PLC based controlled panel unit which houses all the
3.1.1 electrical and electronics accessories for the complete control and Vendor to Confirm
automatic operations
Control panel side and Layout showing complete details shall be
3.1.2 Vendor to submit
submitted.
Machine shall be provided with main switch with key and signal
3.1.3 Vendor to Confirm
light.
4.0 OPERATOR PENDANT & MANUAL CONTROL :
The Operator Pendant provided with all the controls relevant for
operator functions like Emergency stop,On/Off,Cycle
4.1 Vendor to confirm
start/Stop,Weld on/Off,Side beam carraige speed control,joy stick for
Cross Slide adjustment,Auto/manual,etc.
First filling of all required Oils & Grease etc. to be supplied by
5.0 vendor. Indigenous (Indian) source or Indian equivalent and Vendor to confirm
specifications of oils/ greases are also to be provided by the vendor.
Lubrication shall be life time lubricated wherever possible. Other
5.1 lubrication points shall be of automatic type. Details shall be Vendor to confirm
submitted.
6.0 ELECTRICAL :
415V + 10% / -10%, 50HZ +/-3 HZ, 3 Phase AC (3 wire system with
out neutral) Power Supply Voltage will be provided by BHEL at a
single point near the machine, as per layout recommended by
Vendor. All types of cables, connections, circuit breakers etc.
6.1 required for connecting BHEL's power supply point to different parts Vendor to confirm
of the machine/control cabinets, shall be the responsibility of vendor.
Requirement of grounding/earthing with required material details is
to be informed by vendor well in advance so that same could be
incorporated during construction of foundation.
Tropicalisation: All electrical / electronic equipment shall be
7.0 Vendor to confirm
tropicalized
All electrical & electronic control cabinets & panels should be dust
7.1 Vendor to confirm
and vermin proof
All electrical components in the cabinets should be mounted
7.2 Vendor to confirm
systematically
7.3 Motors shall conform to IEC or Indian Standards Vendor to confirm
All cables and cable trays required for the machine should be
7.4 Vendor to confirm
included in the offer.
Vendor should ensure the proper earthing for the machine and its
7.5 Vendor to confirm
peripherals.
The electrical components used shall be from reputed international
7.6 makes such as Siemens / Telemechanique / Merlin Gerin / GE/ ABB Vendor to confirm
and shall be accordance with DIN/IEC Standards.
8.0 SAFETY ARRANGEMENTS:
Following safety features in addition to other standard safety
features should be provided on the machine:
Machine should have adequate and reliable safety interlocks /
devices to avoid damage to the machine, work piece and the Vendor to furnish details
8.1
operator due to the malfunctioning or mistakes. Details shall be
submitted in the technical bid.
8.2 Welding operation control through hand switch
In case of overloads due to wrong manoeuvres /malfunctions the
8.3
machine should stop to avoid damage to machine and man.
Detailed list of safety alarms / indications provided on the machine
8.4
shall be submitted along with the offer.
All the pipes, cables etc. on the machine should be well supported
8.5 and protected. These should not create any hindrance to machine
operator's movement for effective use of machine.
Emergency Switches at suitable locations as per International Vendor to furnish details
8.6
Norms should be provided.
Necessary protection shall be provided to prevent from over
8.7
loading.

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 Vendor to furnish details

S No. Description - BHEL's Requirement Specified Offered Deviations Remarks

Automatic Welding Machine to have adequate Safety Guards
8.8
and interlocks. Bidder to submit details on these arrangements
ENVIRONMENTAL PERFORMANCE OF THE MACHINE :
The Machine shall conform to following factors related to
environment :
(a) Maximum noise & (b) maximum fume level shall be as per the
national/ international norms. This will be measured as per
9.0
international standards like DIN 45635-16. Supplier to mention the Vendor to confirm
requirement of accoustic chamber/Enclosure separately and
demonstrate compliance to fume & noise level, if so required.
(b) If any safety / environmental protection enclosure is required it
should be built in the machine by the vendor.
10.0 TOOLS FOR ERECTION, OPERATION & MAINTENANCE :
Special tools and equipment required for erection of the machine
shall be brought by the vendor. Necessary tools like Torque Wrench,
10.1 Spanners, Keys, grease guns etc. for operation and maintenance of Vendor to agree
the machine should be supplied. List of such tools should be
submitted with offer
11.0 SPARES:
Item wised breakup of (1) standard-mechanical, hydraulic, electrical
and electronic accessories & spares (included in Basic machine
cost),(2) Essential -spares/accessories required for the Purpose and
(3)Optional in sufficient quantity as per recommendation of Vendor
for 5 years (After initial 24 month's Guarantee period)of trouble free
operation on three shifts continuous running basis should be offered
11.1 by vendor.If machine or control is likely to become obsolete in this Vendor to agree
period, the vendor should inform BHEL sufficiently in advance and
provide drawings of parts / details of spares & suppliers to enable
BHEL to procure these in advance, if required
The list to include following, in addition to other recommended
spares: (Unit Price of each item of spare should be offered in the
price bid)

a) Mechanical Pneumatic & Hydraulic Spares: All types of

Pumps, Valves, Pressure Switches, Transducers, Flow Switches, Vendor to confirm
Filters, Seals, O-rings, Hydraulic Hoses etc. If required.

b) Electrical /Electronics: All types of Relays, Contactors,

Proximity Switches, Push Buttons, Indicating Lamps, Semiconductor Vendor to confirm
Fuses, Special Fuses, Circuit Breakers, Main Power Switch, etc.
Vendor to supply 2 Sets of Electronic cards or PCBs or LCD
11.2 Monitors, Modules or PLCs or Display Boards if used in the Vendor to confirm
machine along with machine as essential spares.
Recommended set of standard & optional spares for all
11.3 Vendor to confirm
attachments are to be offered with details.
Vendor to confirm that complete list of spares for machine and
accessories, along with specification / type / model, and name &
11.4 Vendor to confirm
address of the spare supplier shall be furnished along with
documentation to be supplied with the machine
DOCUMENTATION :
Three sets of following documents (Hard copies) in English
11.6 Vendor to confirm
language should be supplied along with the machine. Only originals
shall be supplied. Photocopies will not be accepted.
11.7 Operating manuals of Machine Vendor to confirm
11.8 Programming Manuals of Machine Vendor to confirm
Detailed Maintenance manual of machine with all drawings of
machine assemblies/sub-assemblies/parts including Electrical /
11.9 Pneumatic/ Hydraulic circuit diagrams. All Assembly/ Sub Assembly Vendor to confirm
Drawings including ladder drawing shall be supplied with the parts
list.
11.10 Manufacturing drawings for all supplied Tables frame ,fixtures etc. Vendor to confirm
Catalogues, O&M Manuals of all bought out items including
11.11 Vendor to confirm
drawings, wherever applicable.
11.12 Detailed specification of all rubber items and hydraulic/lube fittings. Vendor to confirm
11.13 PLC program on CD, Vendor to confirm
Complete Master List of parts used in the machine shall be
11.14 Vendor to confirm
submitted by the vendor.
One additional set of all the above documentation on CD ROM,
11.15 Vendor to confirm
wherever possible.
12.0 TRAINING
BHEL Persons should be trained at supplier's Works for mutually
agreed period in the area of
(a) Electrical, Electronic maintenance for machine & other supplied
12.1 equipments Vendor to confirm
(b) Mechanical & Hydraulic maintenance of the machine & other
supplied equipments
(c) Operation of the machine & other supplied equipments.
12.2 Fare, boarding & lodging for the trainees shall be borne by BHEL. Vendor to confirm

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S No. Description - BHEL's Requirement Specified Offered Deviations Remarks
Competent experts shall be arranged by the vendor during training
12.3 Vendor to confirm
for satisfactory & effective training of BHEL personnel.
12.4 Vendor to quote for training on per diem basis Vendor to confirm
13.0 FOUNDATION :
13.1
Vendor shall submit the layout drawing within one month from the
date of Letter of Intent (LOI) / P.O. Layout should contain layout of
the machine and load points including details viz. static / dynamic
load details etc. The layout should consist of all requirements
pertaining to complete machine including space requirement for
Voltage Stabilizer, Isolation Transformer, Air compressor, Chip Bin &
any other accessories. Foundation of the machine if required will be Vendor to agree
designed by supplier. BHEL shall construct complete foundation for
the machine under supervision of supplier and at supplier’s
responsibility. supplier should arrange equipments required for the
testing of foundation, if required . The vendor shall also indicate
detailed specifications of grouting compound and Grouting
procedure etc. for foundation bolts of the machine.
14.0 ERECTION & COMMISSIONING
Supplier to take full responsibility for carrying out the erection, start
up, testing of machine, it’s control & all types of other supplied
equipment, machining of test pieces etc. Service requirement like
power, air & water shall be provided by BHEL at only one point to
14.1 Vendor to agree
be indicated by supplier in their foundation/layout drawings. Other
requirements like crane and helping personnel shall also be
provided by BHEL. Details of these requirements should be informed
by vendor in advance.
Successful working of full capacity of the machine by the supplier
shall be considered as part of commissioning. All tests, as
14.2 Vendor to agree
mentioned at clause 15 & 16 shall form part of the commissioning
activity.
Tools, Tackles, instruments and other necessary equipments
14.3 required to carry out all above activities should be brought by the Vendor to agree
supplier.
Commissioning spares, required for commissioning of the machine
14.4 within stipulated time, shall be brought by the supplier on returnable Vendor to agree
basis.
All Cover Plates required for the machine and its peripherals
14.5 Vendor to agree
including pits, if any, shall be supplied and installed by the vendor.

Portion, if any, of the machine, accessories and other supplied items

where paint has rubbed off or peeled during transit or erection
14.6 should be repainted and merged with the original surrounding paint Vendor to agree
by the vendor. For this purpose, the vendor should supply sufficient
quantity of touch-up paint of various colours of paint used.
Schedule of Erection and Commissioning shall be submitted with the
14.7 Vendor to agree
offer.
Charges if any ,duration, terms & conditions for E&C should be
14.8 Vendor to confirm
furnished in detail separately by vendor along with offer.
15.0 TESTING STANDARD & PROCEDURE
15.1 Welding Quality Test viz.Non Destructive Test( DP , X Ray,)etc
15.2 Repeatability of settings
a) Satisfactory welding should be demonstrated on minimum of
three assemblies each for the smallest and the biggest sizes of the
assemblies b) The sample welded joints should pass through the
Vendor to specify the
macro section test and satisfy the requirements of millivolt drop test
15.3 Standard.
where the difference between parent metal and weld metal value
shall not exceed 10%.
c) Vendor should demonstrate the full penetration welding .

15.4 Any other testing if required

MACHINE ACCEPTANCE: (Tests/Activities should be
16.0 Vendor to agree
Performed by Vendor)
Tests/Activities should be carried out at supplier’s works on the
16.1
machine before dispatch :
The machine should be tested for full load test at supplier works
16.1.1 Vendor to confirm
before despatch.
Demonstration of all features of the machine, control system &
16.1.2 Vendor to confirm
accessories.
16.1.3 Any other tests/activities Vendor to confirm
Tests/Activities should be carried out at BHEL works while
16.2
commissioning the machine :
Full load test to demonstrate the maximum power & capacity of the
16.2.1 Vendor to agree
machine at BHEL works.
16.2.2 Machine should qualify on actual job at min & max size Vendor to agree
Demonstration of all features of the machine, control system &
16.2.3 accessories to the satisfaction of BHEL for efficient and effective use Vendor to agree
of the machine.
Training of BHEL machine operators in operation of complete
16.2.4 machine & accessories etc by the supplier's experts / engineers Vendor to agree
during their stay at BHEL works.

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S No. Description - BHEL's Requirement Specified Offered Deviations Remarks
Demonstration by actual use of all supplied attachments and
16.2.5 Vendor to agree
accessories to their full capacity for actual jobs.
17.0 PACKING:
Rigid packing for all items of complete machine with all Accessories
and other supplied items to avoid any damage/loss in transit. When
17.1 Vendor to confirm
machine is despatched in containers, all small loose items shall be
suitably packed in boxes.
18.0 GUARANTEE :
Guarantee for 24 months from the date of acceptance of the
machine at BHEL works . During this Guarantee period at least 2
visits per year and/or whenever called by BHEL (within 24 hours
of call) by the service engineer of the supplier to be made & the
18.1 Vendor to confirm
parts, items, spares etc. needing replacement to be replaced by the
supplier free of cost. In support a Performance Bank Guarntee of
10% of Basic Value of P.O. valid for 24 months from the date of
commissioning will have to be furnished by supplier
19.0 GENERAL :
19.1 Machine Model Vendor to furnish
19.2 Total connected load (KVA): Vendor to furnish
Floor area required (Length, Width, Height) for complete machine &
19.3 Vendor to furnish
accessories
Painting of Machine / Electrical Panels : RAL 6011 Apple Green
19.4 Vendor to confirm.
(Polyurethane Paint)
19.5 Total weight of the machine Vendor to furnish
19.6 Weight of heaviest part of machine Vendor to furnish
19.7 Weight of the heaviest assembly / sub-assembly of the Machine Vendor to furnish
19.8 Dimensions of largest part/ sub-assembly/ assembly of the machine Vendor to furnish
Detailed catalogues, sketch/photographs of the m/c and
19.9 Vendor to submit
accessories/ attachments should be submitted with the offer.
Formula for calculating required time/speed of torch/job for welding
19.10 Vendor to confirm.
Aluminium plates to be furnished by the vendor.
Hydraulic, Pneumatic & oil pipings should be preferably metallic
except places where flexible pipings are essential. All the pipes
19.11 Vendor to confirm.
required for the same shall be included in the standard scope of the
machine.
Signature & Seal of Tenderor

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